by Adam_Winstone » Sat Apr 23, 2022 1:26 pm
A couple of points that I would add, although better reading through previous (not done) might rule out:
1. Clutch lever choice, the limited range of some levers can result in poor travel/separation, resulting in you fighting clutch and transmission when trying to change gear.
2. In Sticky's manual, there is a comment from Dean Orton about finding that some gear lever housings benefit from a little work to provide additional clearance to the clutch cable outer and passage, so that the housing and cable don't fight against one another when trying to select gears. I had never experienced such conflict and thought no more about it until I had a gear selection issue that I couldn't resolve.
Sure enough, after trying all else, I revisited the housing (never gave issue previously but I had recently replaced engine) as I noted the cable becoming stressed under rotation force, which improved gear selection dramatically!
I hadn't expected this to be an issue, as the bike had been ok to ride prior to engine replacement, and it is likely that some combination of the new motor's assembly (arm position on spines or other) and cabling was making the issue manifest itself, however, the engine assembly was right and adjustment at that end ok, but a little fettling at the headset resolved the issue.
^... Odd, but worth considering.